Performance footwear

ABSTRACT

The present invention is directed toward footwear including an upper connected to a sole structure. The upper includes two portions formed via compression molding in which textile layers are compressed to form a fabric laminate. One of the upper portions generally defines a seamless heel cup. The other upper portion generally defines a toe cage. The toe cage includes one or more integrated toe guides operable to position a toe of a wearer in a predetermined position within the cavity.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. non-provisional applicationSer. No. 14/458,712, filed on Aug. 13, 2014 and entitled “PerformanceFootwear,” which claims the benefit of U.S. Provisional PatentApplication 61/865,384, filed 13 Aug. 2013 and entitled “PerformanceFootwear”. The disclosures of the above applications are incorporatedherein by reference in their entirety.

FIELD OF THE INVENTION

The present invention is directed toward an article of footwear and, inparticular, to a running shoe.

BACKGROUND OF THE INVENTION

Performance footwear such as running shoes is designed for comfort anddurability. To provide these features, performance footwear is typicallyconstructed from a material or a combination of materials havinginsulative, moisture resistant, and/or abrasion resistantcharacteristics. The processes for constructing performance footwear canbe labor intensive, often requiring sophisticated and expensivestitching and/or injection molding equipment. For example, conventionaluppers may are constructed via stitching, i.e., by cutting materialaccording to a pattern to form a series of individual pieces, and thenstitching the individual pieces of the pattern together to form theupper. The end result is a shoe having a significant number of seams.Seams, which are friction points, are located throughout the upper and,in particular, in the heel and bottom areas. In light of this,conventional footwear requires an insole or other covering to hide thestitched seam along the bottom of the upper.

In another conventional method is formed via injection. This type offootwear is designed for harsh weather conditions (e.g. rubber boots).While generally seamless, this type of footwear is water and vaporimpermeable, resulting in footwear lacking breathability. In the contextof athletic footwear, this process results in wearer discomfort becauseairflow into and out of the shoe is prevented. Accordingly, heat andperspiration from the wearer cannot be evacuated to the ambientenvironment, resulting in wearer discomfort.

Thus, it would be desirable to provide performance footwear that islightweight, breathable, and durable, but avoids seams and/or stitchesin the heel and/or footpad areas.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed toward footwear including an upperconnected to a sole structure. In an embodiment, the upper includes afirst upper portion secured to a second upper portion. Each upperportion is formed via compression molding in which textile layers arecompressed to form a fabric laminate. With this process, themacrostructure and microstructure of each portion upper is controlled.Specifically, the first upper portion includes a macrostructure thatgenerally defines the insole and heel cup of the upper. The heel cup,moreover, is seamless. The second upper portion includes amacrostructure that generally defines the instep and toe cage areas ofthe upper. The toe cage may further include an engineeredmicrostructure. In an embodiment, the toe cage includes one or moreintegrated toe guides operable to position a toe of a wearer in apredetermined position within the cavity.

In another embodiment, the upper is configured with a microstructureformed of protrusions along the interior and/or exterior upper surface.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1A is a side perspective view an article of footwear in accordancewith an embodiment of the invention, showing the medial footwear side(footwear configured for a left foot).

FIG. 1B is a side view in elevation of an article of footwear inaccordance with an embodiment, showing the lateral side footwear side(footwear configured for left foot).

FIG. 1C is a rear perspective view of the article of footwear shown inFIG. 1B.

FIG. 2 is an exploded view of the article of footwear shown in FIG. 1A.

FIG. 3 is a top perspective view of the planum portion of the upper inaccordance with an embodiment of the invention (upper configured for theright foot).

FIG. 4 is a top perspective view of the dorsum portion of the upper inaccordance with an embodiment of the invention (adapted for right foot).

FIG. 5A is a perspective, close-up view of a toe cage in accordance withan embodiment of the invention.

FIG. 5B is top plan view of the toe cage of FIG. 5A.

FIG. 5C is a cross sectional view of the toe cage shown in FIG. 5A.

FIG. 6 illustrates a cross sectional view of compression moldingapparatus, showing upper formation.

FIG. 7 is a top perspective view of a sole structure in accordance withan embodiment of the invention, showing the medial side of the solestructure (adapted for the right foot).

FIG. 8 is a bottom plan view of a sole structure in accordance with anembodiment of the invention.

FIG. 9A is a perspective, close-up view of a toe cage in accordance withan embodiment of the invention.

FIG. 9B is a top plan view of the toe cage of FIG. 9A.

FIG. 9C is a cross-section view of a toe cage in accordance with anembodiment of the invention.

Like numerals identify like components throughout the figures.

DETAILED DESCRIPTION OF THE INVENTION

Turning to FIGS. 1A, 1B, and 1C, an article of footwear 10 in accordancewith an embodiment of the present invention includes an upper 105coupled to (e.g., mounted on) a sole structure 110. The article offootwear 10 defines several regions corresponding with various parts ofa foot. Specifically, the footwear 10 defines a rear footwear region 115generally corresponding with the rear of the foot (e.g., the hindfootincluding the heel); an intermediate footwear region 120 disposedforward the rear region and generally corresponding to the midfoot(e.g., the arched, instep, and ball areas of the foot); and a forwardfootwear region 125 disposed forward of intermediate region andgenerally corresponding to the forefoot (e.g., the toes of the foot).The article of footwear 10 may further include a fastener 127 (e.g., ashoe lace) and a heel counter 129 (discussed in greater detail below).

The upper 105 includes a heel 130, a lateral side 135, a medial side140, an instep 145, and a toe cage or box 150. The heel 130 forms a rearportion of upper 105 and is generally configured to extend along theheel of the foot. The lateral side 135 spans through a longitudinallength of footwear 10, extending along the lateral side of the foot.Similarly, the medial side 140 extends along the longitudinal length offootwear 10 such that it extends along the medial side 140 of the foot.The instep 145, positioned between the lateral side and the medial side,extends over the instep of the foot and generally includes tongue 147.Finally, the toe cage 150 defines the forward area of the upper 105,being configured to house the toes of the foot.

The upper 105 defines a cavity that receives the foot. Specifically, theheel 130, lateral side 135, medial side 140, instep 145, and toe cage150 cooperate to define an interior cavity into which a foot is insertedby way of an access opening or collar 155. The collar 155 may befinished with, e.g., fabric tape applied via adhesive. In an embodiment,a strip of material is applied around an inside edge of collar 155 toallow the edge of collar to be finished without a binding to reducefraying and/or to help collar adhere to the skin of the user. Thematerial may be an elastomeric and/or tacky polymer such as, but notlimited to, polyurethane, silicone, nylon, and polyester.

In the embodiment shown in FIG. 2, the upper 105 is formed of twoportions, a first or planum portion 205 coupled (e.g., connected) to asecond or dorsum portion 210 via a seamless coupling member 215.Referring to FIG. 3, the planum portion 205, which generally covers theheel and planum areas of the foot, includes a heel cup 315A and a planumsupport 315B extending forward from the heel cup. The heel cup 315A is aself-supporting structure configured to surround the lateral side,medial side, and bottom of the heel bone (calcaneus). As shown, the heelcup 315A is defined by a wall 325 with a lateral portion 330Aterminating in a forward lateral edge 335A and a medial portion 330Bterminating in a forward medial edge 335B. The vertical wall 325 curvesforward at its lower end, transitioning to the planum support 315B, withthe vertical wall and planum support cooperating to define a curved heelpocket or cup 340. In a further embodiment, the vertical wall may curveinward (toward the foot) as it travels upward (in the direction of thecollar 155).

The planum support 315B extends forward from the curved heel pocket 340to define a midfoot support region 345A and a forefoot support region345B. The midfoot support region 345A may be a generally U-shapedstructure defining a bottom wall 350; a generally vertical, lateral tabor wall 355A terminating in a lateral forward edge 360A; and a generallyvertical, medial tab or wall 355B terminating in a medial forward edge360B. The forefoot support region 345B defines a generally planar memberconfigured to span the ball and toes of the foot.

The heel cup 340 of the planum portion 205 is seamless. Conventionalfootwear typically includes a seam (e.g., a welded seam or a stitchedseam) within the heel cup. For example, a conventional heel cup includesa vertical seam along the connection between two heel halves (lateraland medial halves) and a longitudinal seam along the connection betweenthe two halves of the footpad. The heel 130 of the article of footwear10 discussed herein, in contrast, does not include a seam. Instead, theheel 130 is a unitary structure shaped to define a seamless, unitaryheel cup 340. In a further embodiment, the entire planum portion 205 isseamless, with the heel cup 315A and the planum support 315B forming aunitary and/or one-piece structure.

Additionally, the upper 105 in accordance with an embodiment of theinvention is sockless, defining a shell that encloses the foot.Conventional footwear typically includes an upper with an opened bottomthat is attached (e.g., stitched) to the sole. A layer of material isthen set inside the footwear to create a cushioned layer between thesole and the foot that hides the joint between the upper and the solestructure. In contrast, the “insole” of the article of footwear 10 inaccordance with an embodiment of the invention is effectively integratedinto the upper 105 such that the heel and insole form a unitarystructure (e.g., the interior layer of the textile laminate forming theupper 105 functions as the sock). Thus, no further sock or insole isrequired.

Referring to FIG. 4, the dorsum portion 210, which generally covers thedorsum of the foot, includes a proximal section 405A and a distalsection 405B. The proximal section 405A generally defines the lateral135, medial 140, instep 145 areas of the upper 105. As illustrated, theproximal section 405A of the dorsum portion 210 includes a lateral flap410A and a medial flap 410B separated by a central opening 415. Thelateral flap 410A is a generally planar member including a plurality oftabs or loops 420A-420D extending laterally inward (toward the centralopening 415). A loop includes two fabric elements oriented parallel toeach, being fixed (connected) to each other at twolongitudinally-spaced-apart locations. With this configuration, eachloop 420A-420D defines a channel through which the fastener 127 may bepassed, thereby creating a connection point for the fastener (see FIG.1B). It should be understood, however, that other fastener connectionssuch as eyelets/grommets 422 may be utilized to secure the fastener 127.

The proximal section 405A further includes a tongue connection 425 towhich a tongue 147 may be attached (e.g., via thermal tape). The tongue147 may be formed of materials similar to that of the upper, and may beformed utilizing the same method (discussed in greater detail below).Specifically, the tongue 147 may include a three dimensionalmacrostructure where the tongue curves in the transverse dimension(e.g., it curves along its width) such that it follows the contour ofthe foot instep 145. The tongue 147, moreover, may be configured suchthat it tapers along its transverse and/or longitudinal edges, beingthicker in the tongue central region and gradually thinning toward itsedges (e.g., the edge may be 1/16 the thickness of the central region).This may be achieved by compressing the fabric laminate of the tongue toa greater degree along the edges, and/or by utilizing a skived foamlayer as the layer of the fabric laminate.

Alternatively, the tongue 147 may be formed of different materialsincluding, but not limited to, fabric, mesh, etc.

In an embodiment, one or more portions 205, 210 of the upper 105 mayinclude perforations to permit the flow of fluid (e.g., air and/orwater) therethrough. In other embodiments, the upper 105 contains noperforations to lessen or prevent the flow of fluid through the upper.

While not described in detail, it should be understood that the medialflap 410B is a mirror image of the lateral flap 410A, including loopsand/or perforations as explained above.

The distal section 405B of the dorsum portion 210 includes the toe cage150, which covers/houses the toes of the wearer. In the illustratedembodiment, the toe cage 150 includes a generally horizontal top cover435A (configured to span over the toes of the foot) and a rim or lip435B extending downward from the top cover (e.g., the rim may beoriented substantially orthogonal to the cover 435A). The toe cage 150is configured to cooperate with the forefoot support region 345B of theplanum support to define a single cavity within the upper 105 thatreceives all of the toes of the foot. As with the proximal section 405A,the distal section 405B may further include perforations 430 operable topermit fluid flow therethrough.

In an embodiment, the dorsum portion 210 possesses a unitary (one piece)construction. The toe cage 150, furthermore, may be a stitchless,contoured (three-dimensional) structure. In a further embodiment, thetoe cage 150 is seamless.

Each of the planum portion 205 and the dorsum portion 210 may beformed/shaped via a compression molding process (discussed in greaterdetail below). Compression molding permits formation of a textilelaminate having unique geometries (e.g., predetermined macrostructuresand microstructures). That is, in addition to the seamless heel cup 340of the planum portion 205 (macrostructure), the toe cage 150 may furtherinclude an undulating topography defining one or more toe guidesintegrated into the dorsum portion 210 (microstructure). Referring toFIGS. 5A, 5B, and 5C, the toe cage 150 includes a plurality of toeguides 505A, 505B, 505C, 505D, 505E, each operable to position a toe ina predetermined position within the toe cage cavity 507 (e.g., in aspecified lateral position within the upper) and/or in a predeterminedposition relative to an adjacent toe. By way of example, the distalsection 405B of the dorsum portion 210 includes one or more truncatedwalls or partitions (also called a terminal digit baffle) extending intothe toe cage cavity 507. The partitions deflect or guide a toe into apredetermined position relative to the upper 105 and/or adjacent toes.In an embodiment, the partitions extend downward (toward the solestructure 110) from the ceiling of the toe cage 150. In anotherembodiment, the partitions extend upward from the planum support 315B ofthe planum portion 205 (not illustrated).

In a preferred embodiment, the toe guides 505A-505E are defined by aseries of recessed areas and raised areas integrated (e.g., molded) intothe upper 105 and, in particular, the toe cage 150. Specifically, thetop of the toe cage 150 undulates, defining one or more raised areas515A-515E (each having an apex 520A-520E), as well as one or morerecessed areas 525A-525D (each having a nadir 530A-530D). With thisconfiguration, each raised area 515A-515E defines an elongated, openchannel or half cylinder 517A-517E operable to receive a portion of atoe (in a preferred embodiment, a channel 517A-517E does not completelyenclose the toe). The recessed areas 525A-525D that border a raisedarea, moreover, extend downward at a depth sufficient to direct a toeinto the channel 517A-517E of the raised area 515A-515E. Each raisedarea 515A-515E generally aligns with a corresponding toe, while eachrecess 525A-525D generally aligns with an associated space between thetoes. Accordingly, each channel 517A-517E receives a toe of the wearer.Specifically, in the illustrated embodiment, the first toe guide 505A(the channel 517A defined by the raised area 515A) receives the hallux(the big toe), the second toe guide 505B (the channel 517B defined bythe raised area 515B) receives the second toe (the long toe), the thirdtoe guide 505C (the channel 517C defined by the raised area 515C)receives the third toe (the middle toe), the fourth toe guide 505D (thechannel 517D defined by the raised area 515D) receives the fourth toe(the ring toe), and the fifth toe guide 505E (the channel 517E definedby the raised area 515E) receives the fifth toe (the pinky toe). Theouter walls 540, 545 of the cage, moreover, guide the medial (big) toeand the lateral (pinky) toe into its corresponding toe guide 505A and505E, respectively.

The height of each raised 515A-515E and/or recessed 525A-525D area maysimilar among the toe guides; alternatively, the height of the areas maydiffer. That is, the distance measured from the top side of the solestructure 110 (and/or the planum support 315B) to the apex 520A-520E ornadir 530A-530D may equal or differ. By way of example, the heights ofthe raised areas 515A-515E may successively lessen in the lateraldirection of the shoe, with the first toe guide 505A possessing thegreatest height and the fifth toe guide 505E possessing the lowestheight.

In an embodiment, the nadir 530A-530D extends into the toe cage cavity507 at a depth that enables the partition to interact with(contact/deflect) a toe positioned within the cavity, but still permitspassage of a toe underneath the recess 525A-525D, thereby permitting auser to manually reposition/move/flex toes as desired. Stated anotherway, since the partitions defined by the recessed areas 525A-525D do notextend completely through the toe cage cavity 507, a space or gap existsbetween the distal end of the partition (i.e., the nadir 530A-530D ofthe recessed area 525A-525D) and the planum support 315B to form a nadiror recess gap 532. The recess gap 532 may possess any height h1 suitablefor its described purpose. By way of example, the height h1 of therecess gap 532 is selected to permit a user to manually reposition thetoes within the toe cage 150 if desired. The height h1 of the recess gap532 may be consistent across each recessed area 525A-525D, or may differbetween recessed areas.

Similarly, the apex height h2, i.e., the height h2 measured from theplanum support 315B to the apex 520A-520E of a raised area 515A (theapex gap), may be any suitable for its described purpose, and may be thesame or differ between toe guides 505A-505E. In the illustratedembodiment, the apex height h2 is greater than the recess height h1.

With this configuration, each toe guide 505A-505E—each raisedarea—possesses a depth effective to receive a portion of a toe (i.e.,the upper portion/area of the toe). By way of example, the depth of thetoe guide 505A-505E may be configured to receive/enclose from about 10%to about 50% of a toe, and preferably about 15%-40% of the toe.

Each raised area 515A-515E and recessed area 525A-525D may extendlongitudinally along the toe cage 150, being laterally spaced from eachother in the transverse direction (i.e., across width of shoe) such thatthe walls are generally parallel. The toe guides 505A-505E may possessany length suitable for its described purpose. By way of example, eachraised area 515A-515E and recessed area 525A-525D may extend from thefront of the toe cage 150 and terminate proximate the instep 145 (e.g.,proximate the tongue connection 425 of the article of footwear 10).

As shown, each raised area 515A-515E and recessed area 525A-525D definea gently curved surface, being contoured with the outer surface of atoe. The width w1, w2, w3, w4, w5 of each toe guide 505A-505E may be thesame, or may differ to accommodate the differing widths of the toe onthe foot. By way of example, the width w1 of the first toe guide 505A(configured to receive the big toe) may be greater than the width w3 ofthe third toe guide 505C (configured to receive the middle toe). Thewidth w3 of the third toe guide 505C, moreover, may be greater than thewidth w5 of the fifth toe guide 505 E (configured to receive the pinkytoe).

With the above described configuration, the toe guides 505A-505Emaintain each toe in its natural position, guiding or limiting thelateral movement of each toe. In operation, as a wearer inserts a footinto the proper article of footwear, the partitions formed by therecessed areas 525A-525D guide each toe into its corresponding raisedarea channel. During use (i.e., with the foot at rest or in motion), thepartitions continuously guide its associated toe to the raised areachannel to maintain the toe within its respective guide 505A-505E.Stated another way, the toe guides 505A-505E may be configured tolaterally flex each toe, driving adjacent toes away from each other suchthat each toe may be slightly spaced/separated from its adjacent toes.Additionally, the toe guides 505A-505E maintain the position of each toeby preventing the lateral movement of a toe during use (e.g., whilerunning). Accordingly, the toe guides 505A-505E stabilize each toe,reducing the internal movement or slipping of the user's foot andfacilitating the ability of each individual toe to provide balance.This, in turn, optimizes the performance and comfort of the wearer.

The configuration of the upper 105 described above provides a single,open cavity toe cage 150 that receives all the toes and, whilerestricting their lateral movement, still permits a user to manipulatethe toes and reposition them within the toe cage cavity 507 as desired.This is in contrast to known upper configurations that provide a seriesof individual cavities, one for each toe. In these configurations, eachtoe is completely enclosed within its own cavity, with each cavity beingindividually articulable. Thus, conventional configurations do notprovide a single, open cavity.

With the above-described upper configuration, two levels of motion areprovided during use. First, the entire toe cage 150 moves as a singleunit, pivoting about the ball of the foot (e.g., along the flex line ofthe sole structure 110, discussed in greater detail below). Second,while the natural movement of the toes is still permitted, the toes arespread within the toe cage by the toe guides 505A-505E, which alleviatestoe crowding. This, in turn, increases wearer comfort during use andprovides a more natural (barefoot) feel to the wearer.

As noted above, the planum portion 205 may be connected to the dorsumportion 210 in a seamless and/or stitchless manner. In an embodiment, acoupling member 215 couples (e.g., connects) the dorsum portion 210 tothe planum portion 205. Specifically, the upper 105 includes a lateralcoupling member 215 disposed along the lateral side of the upper and amedial coupling member disposed along the medial side of the upper. Byway of example, the portions 205, 210 of the upper 105 may be connectedvia a fabric tape such as a thermal adhesive tape (e.g., BEMIS seamtape, available from Bemis Associates, Inc., Shirley, Mass.). In apreferred embodiment, the coupling member 215 comprises fabric similarto the fabric forming the upper (e.g., polyester, spandex, etc.).

As noted above, the flaps of the dorsum portion 210 are generallycontoured to the edges 355A, 355B, 360A, 360B of the planum portion 210.Accordingly, the planum portion 205 mates with the dorsum portion 210.Specifically, the lateral 410A and medial 410B flaps of the dorsumportion 210, cut in a fashion complementary to that of the planumportion 205, are each brought into adjacent relationship with thelateral 330A, 355A and medial 330B, 355B walls of a heel cup 340 and theplanum portion 205, respectively. The corresponding edges 235A, 235B,260A, 260B are stitched together, and the coupling member 215 (e.g.,fabric tape) is applied such that the coupling member bridges theconnection between the portions 205, 210, covering the stitching.Preferably, the coupling member 215 is disposed on both the interior andexterior surfaces of the upper 105. Heat is then applied to the couplingmember 215 to seal the seam, fixing the member to the upper 105.

With this configuration, the coupling member 215 provides a seamlessconnection that minimizes and/or eliminates the friction caused byconventional (exposed) seams. That is, a seamless connection is providedbecause the coupling member 215 creates a generally uninterrupted and/orcontinuous surface along the interior surface and/or exterior surface ofthe upper 105.

Alternatively, the planum 205 and dorsum 210 portions may be connectedwithout stitching, instead utilizing a thermoplastic film that traversesthe seam between adjacent portions, bonding the portions 205, 210together (e.g., SEWFREE tape, available from Bemis Associates, Inc.,Shirley, Mass.).

In other embodiments, ultrasonic welding could be utilized. In anembodiment, individual pieces are joined by ultrasonic welding, and theweld is covered by a strip of heat sealable film.

In either embodiment, the coupling member 215 may possess a curved orundulating shape to track the contours of the connected upper portions205, 210.

Once formed, the resulting upper is coupled (e.g., mounted) to the solestructure 110, e.g., via an adhesive, welding (e.g., ultrasonicwelding), etc.

The upper 105 may comprise any materials suitable for its describedpurpose. In particular, the upper 105 may be formed of material capableof forming a three dimensional structure as described above (e.g., astructure including a toe guide). By way of example, the upper 105 maybe formed of a fabric laminate. By way of further example, the upper 105may be formed of fabric laminate that is capable of being shaped viacompression molding. By way of still further example, the upper 105 isformed of a fabric lamination including a foam layer.

Compression molding is a method of molding in which the molding materialis first placed in an open, heated mold cavity. The mold is closed witha top force or plug member, pressure is applied to force the materialinto contact with all mold areas, while heat and pressure are maintaineduntil the molding material has cured. An exemplary compression moldingapparatus is illustrated in FIG. 6. As shown, the compression moldingapparatus 605 includes a first or female molding portion 610 configuredto receive a second or male molding portion 615 possessing a shapecomplementary to the shape of the first molding portion. The apparatus605 may be utilized to shape a single layer, or may be utilized to shapea multilayered structure. In the embodiment shown in FIG. 6, the formedupper 105 includes three layers—an outer or exterior layer 620, a middleor intermediate layer 625, and an inner or interior layer 630. By way ofexample, the exterior layer 620 may be a breathable, synthetic fabric(e.g., a polyester fabric), the intermediate layer 625 may beopen-celled foam (e.g., ethylene vinylacetate), and the interior layer630 may be a breathable, synthetic fabric (e.g., a polyester fabric).

Additionally, the exterior layer 620 and/or the interior layer 630 mayfurther include an elastic fiber (e.g., spandex or elastane) to providethe layers with elastic properties. In an embodiment, the exterior layer620 is fabric including 85% polyester and 15% spandex (weight 215 g/m²),the intermediate layer 625 is polyurethane foam, and the interior layer630 is fabric including 79% polyester and 21% spandex (weight 210 g/m²).

The exterior 620 and interior 630 fabric layers may possess similar ordifferent properties such as elongation properties. By way of example,the exterior layer 620 may possess greater elongation along its lengththan the interior layer 630, while the interior layer 630 may possessgreater elongation along its width then the exterior layer 620.

In other embodiments, the outer 620 and/or inner 630 layers may beformed of leather, GORETEX, etc.

Upon compression (and the application of heat), the layers 620, 625, 630adhere, forming a fabric laminate. Additionally, the fabric laminateconforms to the shape of the molding portions 610, 615, permanentlyholding its shape. In this manner, the planum portion 205 and dorsumportion 210 of the upper 105 may be formed, possessing the shape of themold.

This formation process enables the creation of the macrostructure of theupper 105 (the general shape of the planum 205 and dorsum 210 portionsof the upper), but also the microstructure of the upper (the toe guidestructure). In an embodiment, the microstructure may further includeprotrusions, e.g., generally rounded nubs or bosses extending outwardfrom either the interior surface or the exterior surface of the upper.When extending from the exterior surface of the upper, the protrusionsmay provide abrasion resistance or impact protection in specified areasof the upper. In addition, the protrusions may define contact areasconfigured to improve contact with a ball during game play (e.g., asoccer ball, kickball, etc.).

When disposed on the interior surface of the upper 105, the protrusionsact as spacers to create air gaps or channels between the upper and thefoot of the wearer, enabling airflow within the channels. Theprotrusions are integrated into the upper 105, being formed as theresult of the shape of the mold portions 610, 615 (a negative of theprotrusion pattern is formed into the appropriate mold portion 610,615). The protrusions may be any size and shape suitable for theirdescribed purpose, and may be disposed in any predetermined patternalong a portion of the upper, or along the entire upper 105.

In addition, a reinforcing element may be inserted between the interiorlayer 630 and the foam layer 625 and/or the exterior layer 620 and thefoam layer. A reinforcing element is a component possessing rigiditythat is equal to or greater than that of the interior layer/and/orexterior layer. By way of example, a generally U-shaped reinforcingplate may be located within the heel portion of the upper 105. Thereinforcing plate, formed of, e.g., fabric or plastic, providesadditional support to the ankle, functioning as an internal heelcounter. Additionally, the plate may provide protection to the anklethat may occur during use (e.g., contact with other shoes).

The sole structure 110 is a durable, wear-resistant component configuredto provide cushioning as the article footwear 10 impacts the ground. Inan embodiment, the sole structure 110 may include an insole, a midsole,and an outsole. In other embodiments, the sole may be a unitary and/orone-piece structure. Turning to the embodiment illustrated in FIG. 7,the sole structure 110 includes a first, upper-facing side 705 (alsocalled a top side) and a second, ground-facing side 710 (also called abottom side). The top side 705 may possess a generally planar surfacehaving a gently curved rim or wall 715 that defines the sole perimeter.

The sole structure 110 may further include a heel counter 129 adapted tosurround the heel portion of the upper 105. The heel counter 129 is anexternal strengthening device in the heel area of the upper 105configured to control and stabilize the wearer's heel inside the shoeand to minimize excessive supination or pronation of the foot. As shown,the heel counter 129 includes a generally central leg 720 mounted on andextending distally (upward) from the first side 705 of the solestructure 110. A pair of arms 725A, 725B extends from the distal portionof the central leg. Specifically, a first arm 725A extends laterallytoward the lateral side of the footwear and a second arm 725B extendslaterally toward the medial side of the footwear. As shown, each arm725A, 725B is generally horizontal, curving outward (radially from thelongitudinal axis of the sole structure) in the forward direction.

The first arm 725A terminates in a first lateral leg 730A. Similarly,the second arm 725B terminates in a second lateral leg 730B. Each leg730A, 730B extends downward (toward the sole structure 110), beingangled slightly forward (toward the toe cage 150). The proximal end ofeach lateral leg 730A, 730B, similar to that of the central leg 720, ismounted on the top side 705 of the sole structure. With thisconfiguration, the heel counter 129 defines a cage structure having afirst lateral window 735A on the lateral side of the shoe and a secondlateral window 735B on the medial side of the shoe. As shown, the heelcounter 129 may possess a generally cupped shaped, with each leginitially curving outward, beyond the rim of the sole structure, thencurving inward.

The heel counter 129 may be formed of any material suitable for itsdescribed purpose. By way of example, the heel counter 129 is formed ofa thermoplastic elastomer such as ethylene vinyl acetate orpolyurethane. The heel counter 129, moreover, may be flexible,semi-rigid, or rigid. With this configuration, the heel counter 129provides rearfoot stability, preventing injury and prolonging the lifeof the article of footwear.

Referring to FIG. 8, the bottom side 710 of the sole structure 110 maydefine a generally planar surface. The surface of the bottom side 710,moreover, may be textured. In the illustrated embodiment, the bottomside 710 of the sole structure 110 includes a plurality of frictionridges 805 disposed along the sole in a predetermined pattern. By way ofexample, the friction ridges 805 may be provided in a fingerprintpattern including one or more of an arch pattern, a loop pattern (rightor left), and/or a whorl pattern.

Additionally, the bottom side 710 of the sole structure 110 may includeone or more recesses formed therein. In the illustrated embodiment, thebottom side 710 of the sole structure 110 includes a first,generally-transverse recess or flex line 810 disposed forward of theheel and a second, generally-transverse recess or flex line 815 disposedrearward of the toe cage 150 (e.g., forward of the ball of the foot).The first 810 and second 815 flex lines are configured to provideflexure to the sole, enabling movement (pivoting) along the lines.Additionally, the bottom side 710 of the sole structure 110 may furtherinclude one or more of a continuous (closed-loop) recess 820 disposed atan intermediate location between the transverse recesses 810, 815 (e.g.,proximate the plantar fascia region of the foot) and a plurality oflongitudinal recesses 825 disposed at selected locations along the solestructure 110.

The sole structure 110 may be formed of a single material or may beformed of a plurality of materials. By way of example, the solestructure may include a primary structure formed of a first material(e.g., ethylene vinyl acetate) and a secondary structure formed of asecond material (e.g., thermoplastic polyurethane). In an embodiment,the primary structure is a midsole and the secondary structure is anoutsole. In the illustrated embodiment, the outsole structure 830 isprovided as a series of individual pads disposed at predeterminedlocations along the bottom side 710 of the midsole. The material formingthe outsole 830 differs from that of the material forming the midsole bypossessing different mechanical properties. By way of example, thematerials may possess different relative wear ratios. By way of furtherexample, the materials may possess different Shore Hardness values. Theoutsole pads 830, then, are a secondary structure formed of materialpossessing a different wear rate than that of the material forming theprimary structure. Specifically, the sole structure 110 includes a firsttoe pad disposed proximate the big toe of the wearer, one or more ballpads disposed proximate the ball of the foot and spaced laterally acrossthe sole structure, and a heel pad disposed proximate the heel of thefoot.

While the invention has been described in detail and with reference tospecific embodiments thereof, it will be apparent to one skilled in theart that various changes and modifications can be made therein withoutdeparting from the spirit and scope thereof. For example, portions 115,120, 125 are not necessarily intended to demarcate precise areas offootwear 10 and may simply represent general areas of footwear toprovide a frame of reference.

The upper 105 may possess any dimensions or shapes suitable for itsdescribed purpose. Additionally, the dorsum portion 210 of the upper 105may include any number of toe guides. By way of example, referring toFIGS. 9A, 9B, and 9C, instead of including a toe guide for each toe (allfive toes), the toe cage 150 may include a guide for a single toe. Asshown, the toe cage includes a single toe guide 905 is provided thatreceives the big toe. The toe guide is defined by the raised area 910bounded by a recessed area or partition 915 on one side and the medialouter wall 920 of the toe cage on the opposite side, thereby forming anopen channel 925 that receives a portion of the toe (i.e. the channeldoes not completely enclose the toe). With this configuration, the bigtoe is directed into the toe guide 905, with the remaining toes (thesecond through fifth toes) being positioned within the remaining area935 of the toe cage 150. Accordingly, the big toe is slightly separatedfrom its adjacent (second) toe and/or is the lateral positioned of thetoe is maintained during use. The second through fifth toes are leftunguided (save for the second toe being driven away from the big toe bythe partition). In the illustrated embodiment, the height of the toeguide 905 is greater than the height of the remaining cavity 930. Thewidth w1 of the toe guide 905, moreover, is less than the width w2 ofremaining upper portion 935.

The upper 105 may be stylized as any shoe type. For example, the upper105 may be stylized as a boot or high top athletic shoe that rises abovethe ankle of the wearer, terminating in a collar positioned above theinner ankle bone of the user, thereby providing a gapless gasket sealabove the user's ankle. In such an embodiment, the upper includes adorsum portion and a planum portion as described above.

The materials forming the planum portion 205 of the upper 105 may be thesame or different as that forming the dorsum portion 210 of the upper.For example, the planum portion 205 may be formed of a differentmaterial than the dorsum portion 210. Specifically, the dorsum portionmay be formed of a breathable fabric similar to that described above,which is compression molded to include a plurality of toe guidesoperable to adjust the position of each toe relative to the upper 105.The planum portion 205, however, is composed of non-breathable fabricoperable to prevent the passage of fluid (e.g., water) therethrough.

Additionally, the interior layer 630 and the exterior layer 620 may beformed of the same textile or may be formed of different textiles. Forexample, the interior layer 630 may be a breathable fabric, while theexterior layer 620 may be formed of a natural or synthetic rubber suchas polychloroprene (neoprene). Additionally, the rubber may be blendedwith other materials to provide desired properties (e.g., spandex toimprove elasticity).

The sole structure 110 may further include an extension (operable toprovide toe protection) overmolded onto the toe cage 150 of the upper105.

Also, the planum portion 205 and the dorsum portion 210 portions mayinclude different graphics thereon.

While the planum portion 205 of the upper 105 may be secured to the solestructure 110 via welding or adhesive, all or a part of the planumportion may be secured to the sole structure via stitching.Additionally, while the illustrated embodiment does not include aninsole, an insole may be added, being secured to the planum portion 205of the upper 105 via adhesive, welding, stitching, etc.

As noted above, the upper 105 or portions thereof may be formed of anymaterial suitable for its described purpose. By way of example, theupper 105 maybe formed of flexible textile material of a predeterminedgauge or density. Specifically, the upper 105 or portions thereof may beformed of, for example, knit, woven or non-woven material made usingfibers such as, but not limited to, nylon, polyester, polyurethane andor spandex, with elastomeric properties. The fabric may be breathable(permitting the passage of fluid such as air or water therethrough), ormay be non-breathable (preventing passage of fluid therethrough).

A protective coating may also be applied to seams and/or stitching onother portions of the article of footwear 10 for the purpose ofdurability and to prevent the textile from fraying. For example,stitching that secures the sole structure 110 to the upper 105 may havesuch a coating. Additionally, coatings may also be applied to thetextile upper 105, either internally or externally, to provide enhancedtextile durability in high wear areas such as, but not limited to, theareas above and beneath the toes and the instep.

Additionally, the upper 105 and sole structure 110 may have externalpolyurethane or silicone coatings to provide regional properties such astacky grip for improved ball control.

In other embodiments, the sole structure 110 may include one or more ofan insole, a midsole, and an outsole. For example, the midsole may be apolymer foam material such as ethylene vinylacetate or polyurethane,while the outsole may be formed of various rubber compounds (blownrubber, carbon reinforced rubber) operable to provide a durable,wear-resistant surface for engaging the ground. The insole, a relativelythin cushioning member located within the upper 105 and adjacent to aplantar surface of the foot, is provided to enhance the comfort ofwearer.

Thus, it is intended that the present invention covers the modificationsand variations of this invention provided they come within the scope ofthe appended claims and their equivalents. It is to be understood thatterms such as “top,” “bottom,” “front,” “rear,” “side,” “height,”“length,” “width,” “upper,” “lower,” “interior,” “exterior,” “medial,”“lateral,” and the like as may be used herein, merely describe points ofreference and do not limit the present invention to any particularorientation or configuration.

We claim:
 1. An article of footwear comprising: a sole structure; and anupper secured to the sole structure, wherein the article of footwearincludes a hindfoot section, a midfoot section, and a forefoot section,the sections cooperating to define a cavity operable to receive a footof a wearer, and wherein the article of footwear comprises a singlecompartment toe cage operable to house all toes of the foot, the toecage includes a toe guide extending into the cavity, the toe guideoperable to orient a toe of the foot in a predetermined positionrelative to at least one of the upper and an adjacent toe.
 2. Thearticle of footwear of claim 1, wherein the upper comprises a planumportion including a seamless heel cup and a dorsum portion including thetoe cage disposed above the toes of the foot.
 3. The article of footwearof claim 1, wherein the toe guide comprises a truncated wall extendingdownward from the toe cage.
 4. The article of footwear of claim 1,wherein the upper comprises a laminate comprising an interior layerfacing the cavity, an exterior layer forming an exterior of the shoe,and an intermediate layer disposed between interior and exterior layers,5. The article of footwear of claim 4, wherein at least one of theinterior layer and the exterior layer comprises fabric.
 6. The articleof footwear of claim 1, wherein the upper comprises a planum portionincluding a seamless heel cup and a dorsum portion including the toecage, the toe cage being seamless and disposed above the toes of thefoot.
 7. The article of footwear of claim 6, wherein: the toe cagecomprises an undulating surface defined by a plurality of raised areasand recesses; and the toes of the foot align with the raised area of thetoe cage.
 8. The article of footwear of claim 1, wherein the toe guideis formed into the upper via compression molding.
 9. The article offootwear of claim 1, wherein the toe guide is effective to deflect andreceive a hallux of the foot, thereby separating it from a second toe ofthe foot.
 10. An article of footwear comprising: a sole structure; andan upper secured to the sole structure, the upper comprising: acompression-molded, seamless planum section forming a unitary structurethat extends continuously around a heel, a lateral side, a medial side,and a sole of a foot disposed within the article of footwear, and adorsum section coupled to the planum section, the dorsum sectioncovering an instep, the lateral side, and the medial side of the footdisposed within the article of footwear, the dorsum section including atoe cage having a plurality of toe guides operable to position toes of afoot disposed within the article of footwear in predetermined positionswithin a toe cage cavity.
 11. The article of footwear of claim 10,wherein the dorsum section is compression molded with the plurality oftoe guides of the toe cage.
 12. The article footwear of claim 10, wherethe toe cage is seamless.
 13. The article of footwear of claim 10,wherein the plurality of toe guides are truncated walls that extend atleast partially into the toe cage cavity.
 14. The article of footwear ofclaim 13, wherein the truncated walls extend downward from a ceiling ofthe toe cage into the toe cage cavity.
 15. The article of footwear ofclaim 14, wherein the plurality of toe guides are configured tolaterally flex each toe of the foot disposed within the article offootwear away adjacent toes so that the toes of the foot disposed withinthe article of footwear are separated from adjacent toes.
 16. An articleof footwear comprising: a sole structure; and an upper secured to thesole structure, the upper comprising: a compression-molded, seamlessplanum section including a heel cup and a planum support, the planumsection forming a unitary structure, wherein the planum section isconfigured to extend around a lateral side, a medial side, and a sole ofa foot, and a dorsum section to cover an instep, the lateral side, andthe medial side of the foot, the dorsum section including a toe cagehaving a series of recessed areas and raised areas integrated into thedorsum section.
 17. The article of footwear of claim 16, wherein eachraised area defines an elongated open channel operable to receive atleast a portion of a toe.
 18. The article of footwear of claim 17,wherein the recessed areas extend downward at a depth sufficient todirect a toe into the channel of each of the raised areas.
 19. Thearticle of footwear of claim 18, wherein each of the raised areasinclude an apex, and each of the recessed areas include a nadir, each ofthe nadirs extending into a toe cage cavity at a depth that enables thechannels to interact with the toes positioned within the toe cage cavityand permit passage of a toe underneath the recessed areas.
 20. Thearticle of footwear of claim 16, wherein the series of recessed areasand raised areas define a curved surface contoured with outer surfacesof the toes disposed within the article of footwear.